Whining End Mill

1600 Mike with a 1" HSS cutter?
 
Cutting speed for a full radial diameter cut as you're taking using a rougher with Tin coating is 468 sfm per Niagara Cutter. 468 X 3.82 / 1" = 1787 rpm. I figured going a bit slower and feeding a bit faster would do the trick.

Edit: I often slot aluminum with a rougher on my Sherline mill. Of course, it is only a HSS coarse pitch 4 flute 3/8" diameter roughing end mill but I take full diameter depths of cut and run at 2800 rpm, the top speed my mill will run at. I feed manually and it cuts through aluminum easily with no chatter. Would probably work even better if I could get more than 4000 rpm but I can't. Maybe give it a try?
 
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I tried Mikey, no dice. The chatter just reaches a much higher pitch.
I'm going try a 3/4" end mill next. Maybe later tonight yet.
 
Hmmm, something is not right. Have you looked at the tips of the cutter under magnification? If any of the tips are damaged, that's your problem. I know its new but have a look anyway because a rougher should not be giving you these issues.
 
I will have a look. I only have I think 10x to look.
My thought too, something is not right here.
 
mikey said:
Hmmm, something is not right. Have you looked at the tips of the cutter under magnification? If any of the tips are damaged, that's your problem. I know its new but have a look anyway because a rougher should not be giving you these issues.
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They look perfect Mikey.
I tried a very good used .75" Minicut with an end mill holder. It was fine at .100" but at .200" significant chatter.
Then tried the same end mill in an R8 collet, no problem @.200"DOC.
By the way the 1" Niagara is a five flute. Would that contribute to chatter?
 
You are using the right tool for the wrong job, or vice versa; use a regular end mill.
 
So roughing or corn cob end mills are used for side milling and end mills are used for either. Is there a specific roughing type end mill made fir end milling?
 
Normally an insert type endmill can be used to remove material quickly. Versatile also because you can use inserts that are designed for the material that you are cutting. I think they are available at least down to 1/2 inch. My son has a 1 1/2 inch that he uses to rip through aluminum. 6000 RPM and about 150 IPM feed, 0.100 - 0.250 depth of cut.
 
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